Prospectus

THIRD EXAMINATION FOR RECOGNITION OF

COMPETENT PERSONS FOR
INSPECTION & CERTIFICATION OF BOILERS
11th October 2015 (Sunday)

CENTRAL BOILERS BOARD

Ministry of Commerce and Industry
(Department of Industrial Policy and Promotion)
Govt. of India, New Delhi.

Director & Head

Dr.Ambedkar Institue of Productivity
National Productivity Council
6, Aavin Dairy Road,
Industrial Estate North Phase,Ambattur,
Chennai 600 098
1

Fax: 044

Secretary
Central Boilers Board
Ministry of Commerce and
Industry
(Department of Industrial Policy
and Promotion)
Government of India, New Delhi.
Foreword

The Indian Boilers Act was enacted in 1923 mainly to provide for safety of life and
property from the danger of explosion of boilers and for achieving uniformity in registration
and inspection during operation and maintenance of boilers throughout the country. Since
then there had been no major amendments to the Act. The legislation required changes in
consonance with the evolving developments and changes in the technology of fabrication,
operation, testing and inspection of boilers.
The Indian Boilers (amendment) Act, 2007 which was passed in December, 2007,
has introduced improvements in the provisions of the law to enhance safety norms, to
ensure uniformity in standards of inspection, expediting inspections and reducing
bureaucratic delays by decentralization of inspection of boilers during their manufacture,
erection and use, by allowing inspection and certification by the independent inspecting
authorities.
Notification containing regulations for implementing many provisions of the amendment
Act including for implementing the inspection by the third party inspecting authorities and
competent persons has been published in the Gazette of India on 7th October, 2010.
As per regulations notified on 7th October, 2010, first & second examination was
conducted on 24th April, 2011 & 7th October 2012 respectively for recognition of competent
persons for undertaking inspections & certification of boilers during manufacture, erection
and use by the third party inspecting authorities in India.
Central Boilers Board (CBB), Government of India has authorized National
Productivity Council (NPC) to conduct the third examination for competent persons.
I invite you to register for the third examination for recognition of competent
persons and wish you all very best for your success in the Examination

T.S.G. Narayannen
2

1.0

BACKGROUND:

As per the amendments made in the Boilers Act 1923 vide Gazette Notification by
the Indian Boilers (Amendment) Act, 2007 and the Indian Boiler Regulations, 1950
vide Gazette Notification vide Notification No. G.S.R. 821(E) dated 7th October,
2010, a provision has been made for inspection and certification of boilers and boiler
components during manufacture, erection & use by Competent Persons recognized
by the Central Boilers Board. As per these amendments, a third party Inspecting
Authority in India is required to engage Competent Persons to undertake inspection
and certification of boilers and boiler components during manufacture, erection &
use. Central Boilers Board (CBB), Government of India has authorized National
Productivity Council (NPC) to conduct the first examination for competent Persons.

2.0

PROCEDURE FOR RECOGNITION OF EXAMINATION FOR

COMPETENT PERSONS FOR INSPECTION AND
CERTIFICATION OF BOILERS:
(1) Introduction:-

(a) this regulation provides the requirements for the uniform qualification,
examination, issuance and renewal of Central Boiler Board authorisation to act as a
competent person;
(b) candidates meeting these requirements may be qualified to be issued a
Central Boilers Board authorisation;
(c) Competent persons may be allowed to inspect and certify the boilers
under the Boilers Act during manufacture, erection , operation and maintenance
throughout India.

(2) Minimum qualifications and experience:-

(a) must be a graduate in Mechanical or Production or Power plant or

Metallurgical Engineering from a recognized institution;

(b) minimum five years experience singly or cumulatively in the following

fields related to boilers,(i) Design;
(ii) Manufacture;
(iii) Commissioning;
(iv) Operation and maintenance;
(v) Inspection and certification during manufacture
or operation and maintenance;
(vi) High Pressure Welding-Inspection;

(c) Level-II NDT Certificates from ISNT or any other professional body
recognised by ISNT in Non Destructive methods of testing in radiography
and ultrasonic testing.

(3) Central Boilers Board Examination Process: (i) an examination

shall be conducted by the Central Boilers Board Examination Standing Committee
or an agency or Regional Examination Standing Committees authorised by it, as per
the following methods namely:-

(a) written Examination consisting of design, manufacture, operation and

maintenance of the boiler, Non Destructive Testing Techniques,
inspection and certification of boilers during manufacture and use as
per Indian Boiler Regulations;
(b) viva-voce on the above (30 % weightage shall be given for viva-voce);
(c) the Central Boiler Board will issue a passing grade certificate to the
candidate after passing the examination;
(d) The candidate should obtain a minimum of 50% in each paper with
aggregate of 60% in three papers in the written examination in order
to be eligible for viva-voce.

(ii) application for appearing in the Central Boiler Board Examination

Process shall be made in the format as provided by the Central Boilers Board
Examination Standing Committee at such place and time as decided by the
Central Boilers Board Examination Standing Committee or an agency or
Regional Examination Standing Committees authorised by it.

(4) Central Boilers Board Authorisation Process:(i) the Competent Person shall perform the work without conflict of
interest;
(ii) an applicant for a Central Boiler Board Authorisation shall meet the
following requirements, namely:(a) the applicant shall be in regular employment of, and exclusively
engaged by a Central Boilers Board recognised Inspecting
Authority;
(b) the applicant shall meet the minimum qualification and
experience requirements as referred in sub-regulation 2 of this
regulation;
(c) the applicant shall have taken and passed the Central Boilers
Board examination as referred to in sub-regulation 3 of this
regulation;
(d) the applicant shall apply for an authorisation not later than three
years after passing the Central Boilers Board Examination and a
person whose authorisation has not been issued within the three
year period shall be required to take the Central Boiler Board
Examination and receive a passing grade and
(e)

the maximum age for the Competent Person shall be 65 years

provided the person is medically fit;

(iii) (a)

when the applicant has met the eligibility requirements as

referred in clause (ii) of sub-regulation 4 and at the request of
the applicants employer, a Central Boilers Board authorisation
card and a certificate shall be issued;

(b)

the application for an authorisation shall be on forms obtained

from the Central Boilers Board;
5

(c)

(iv) (a)

a Competent Person may possess only the valid authorisation

card listing one employer;

the validity of each authorisation certificate shall be three years

from the date of issue or in co-terminus with the validity period of
recognition of employing Inspecting Authority whichever is earlier;

(b)

the Competent Person must be in regular employment of the

Central Boiler Board recognised Inspecting Authority failing which
the authorisation lapses;

(c)

if the Competent Person leaves the employment, Central Boilers

Board
Authorisation Card shall be surrendered by the
Inspecting Authority to the Secretary, Central Boilers Board
within a period of seven days;

(d)

the request for renewal shall be made by Competent Persons

employer and the request shall certify that the Competent
Person maintained inspection proficiency by performing or
supervising inspection activity and that the individual has met
the continuing updation requirement as given in clause (f) of this
sub-regulation;

(e)

on change of employment, a request for authorisation card shall

be made by the Competent Persons current employer on forms
obtained from the Central Boilers Board;

(f)

each Central Boilers Board authorised Competent Person, at

least once every three years, shall either attend a Central
Boilers Board seminar or receive other instruction related to
inspections and the instruction may be in any format, e.g.,
classroom, home study, or web-based; the topics may include
any subject of relevance to the inspection process, such as new
methods, products, materials, technology or changes to
construction or repair codes;

(g)

a person whose authorisation has not been renewed for five

years or less may, on proper application from the employer,
have the authorisation reinstated;

(h)

the employer shall provide verification of continuing updation as

mentioned in clause (f) ;
6

(i)

a person whose authorisation has not been renewed for more

than five years shall be required to take the Central Boilers
Board Examination and receive a passing grade;

(v) (a) a Central Boilers Board authorisation may be revoked by the

Secretary, Central Boilers Board for falsification of any
statement contained in any application however the person may
request reconsideration by the Secretary, Central Boilers Board;

(b)when an evaluation reveals that a Central Boilers Board

authorised Competent Person has been negligent in his duty or
has made false statements on forms used for documentation of
his duties, a Central Boilers Board committee formed for the
purpose may examine the evaluation and recommend to the
Secretary, Central Boilers Board, a suitable action against the
Competent Person. The Secretary, Central Boilers Board shall
take the final decision;

(c) if any individual is aggrieved by a decision of the Secretary,

Central Boilers Board , the individual has the right to appeal to
the Central Boilers Board , through the Secretary, Central
Boilers Board and such appeal shall be within thirty days of the
date of the decision;
(d) the decision of the Central Boilers Board shall be binding;

(e) any person aggrieved by,(i) an order made or purporting to be made by a Competent
Person in the exercise of any power conferred by or under the
Act; or
(ii) a refusal of a Competent Person to make any order or to
issue any certificate which he is required or enabled by or under
the Act to make or issue, may, within thirty days from the date
on which such order or refusal is communicated to him, appeal
against the order or refusal to the Chief Inspector of Boilers of
the state in which the boiler is located;
7

(vi)

3.0

a fee established by the Central Boiler Board Examination

Standing Committee shall be paid for each authorisation issued,
renewed or reinstated.

CONDUCT OF A EXAMINATION FOR RECOGNITION OF

COMPETENT

PERSONS

FOR

INSPECTION

AND

CERTIFICATION OF BOILERS AND BOILER COMPONENTS

Central Boilers Board (CBB) has nominated National Productivity Council

(NPC) as the Agency to conduct the examination for competent person.
The examination for recognition of competent persons will be held on
11th October, 2015.

The examination would be conducted for three papers

viz. paper 1,2 & 3 and viva-voce would be subsequently for those who qualify
in the examination.

4.0

ELIGIBILITY

CRITERIA

EXAMINATION
PERSONS

FOR

FOR

FOR

APPEARING

RECOGNITION

INSPECTION

AND

OF

IN

THE

COMPETENT

CERTIFICATION

OF

BOILERS AND BOILER COMPONETS

(a) Must be a graduate in Mechanical or Production or Power Plant or
Metallurgical Engineering from a recognized institution.
(b) Minimum five years experience singly or cumulatively in the following fields
related to boilers,(i)

Design

(ii)

Manufacture

(iii)

Commissioning

(iv)

Operation and Maintenance

(v)

Inspection and certification during manufacture or operation and

maintenance

(vi)

High Pressure Welding-Inspection

(c) Level-II NDT Certificates from ISNT or any other professional body
recognized by ISNT in Non Destructive methods of testing in radiography
and ultrasonic testing.

Note :

(1)

Applicants employed in Central Govt. / State Govt. / PSUs

have to inform their employer in writing before applying

(2) Applicants Age should be as on 31st July, 2015

(3) Training period will not be considered as experience

5.0

SYLLABUS/CURRICULUM

FOR THE EXAMINATION FOR

RECOGNITION OF COMPETENT PERSONS FOR INSPECTION

AND

CERTIFICATION

OF

BOILERS

AND

BOILER

COMPONENTS
a) The examination will be consisting of the following three papers.
1.

Paper 1

(100 marks) would consist of Open book descriptive

examination on Boiler Design Engineering

2.

Paper - II (100 marks) would consist of Open book (IBR 1950 & the
Boilers Act, 1923), Multiple Choice Question (MCQ) type examination
on Boiler Act and Indian Boiler Regulations and their compliance.

3.

Paper - III (150 marks) would consist of No book descriptive

examination

Boiler

Act,

Regulation,

Materials,

Erection,

Commissioning, Operation & Maintenance

b) Viva-Voce 150 marks. The candidate should obtain a minimum of 50% in
each paper with aggregate of 60% in three papers in the written examination
in order to be eligible for viva-voce.

The pass marks for viva-voce

examination is 60%
c) The Central Boiler Board will issue a passing grade certificate to the
candidates after passing the examination
9

6.0

REQUIREMENTS FOR PASSING THE EXAMINATION FOR

RECOGNITION OF COMPETENT PERSONS FOR INSPECTION
AND

CERTIFICATION

OF

BOILERS

AND

BOILER

COMPONENTS
(i) A candidate shall secure at least 50% in each and 60% aggregate marks
in written examination as well as viva-voce in order to pass the examination.
Examination will contain the following papers:
Paper - 1

Paper - 2

Paper - 3

Open book descriptive examination on Boiler

Design Engineering

2 Hours Duration

100 Marks

Open book (IBR 1950 & the Boilers Act, 1923), 1 Hour Duration
Multiple Choice
Question (MCQ) type
examination on Boiler Act and Indian Boiler
Regulations and their compliance

100 Marks

No
book
descriptive
examination
on 3 Hours Duration
Boiler Act, Regulation, Materials, Erection,
Commissioning, Operation & Maintenance.

150 Marks

Viva Voce

150 Marks

10

Schedule of Examination:
Date/Day

Paper

Timings

Paper I

Morning Session

11/10/2015

Examination

09.30 to 11.30

Sunday

(2 Hours)

11/10/2015 Paper 2

Morning Session

Sunday

Open

Marks
book

100

descriptive
examination on Boiler
Design Engineering

11.30 to 12.30
(1 Hour)

Open book (IBR 1950

100

& the Boilers Act,

1923), Multiple
Choice Question
(MCQ) type
examination on Boiler
Act and Indian Boiler
Regulations and their
compliance

11/10/2015 Paper 3

Afternoon

No book descriptive

Sunday

Session

examination

14.00 to 17.00
(3 Hours)

Boiler

150

on
Act,

Regulation, Materials,
Erection,
Commissioning,
Operation

&

Maintenance.
To be decided later

Viva-Voce

Total marks

150
500

11

7.0

EXAMINATION CENTRES:

The examination centres are as follows:S. No.

Centre

1.

Chennai

2.

Mumbai

3.

Kolkatta

4.

New Delhi

The applicants will have to give two choices of examination centre in order of their
preference. If the number of applications for a particular centre is found to be less
than the minimum required number, the examination centre for those applicants can
be shifted to their next preferred centre.
EXAMINATION FEE:
Rs.13,680/- (Rs.12000/- + 1680/- towards service tax @ 14%) (Thirteen thousand six
hundred and eighty only) for General Category candidates and Rs.10,260/(Rs.9000/- + 1260/- towards service tax @ 14%) (Rupees ten thousand two hundred
and sixty only) for SC/ST candidates
The fee shall be paid by Demand Draft favouring National Productivity Council,
payable at Chennai

8.0

REFERENCE BOOKS FOR OPEN BOOK EXAMINATION

The candidates will refer the book on Indian Boilers Regulation for their open book
examination. The candidates should bring their own current edition of IBR Book
without any notes / marks and any other book is not allowed.

The necessary technical data sheets if required would be supplied to the candidates
during the examination.
12

9.0

REGISTRATION PROCESS

Registration for the Certification Examination will be done on receipt of the filled-in
application form along with requisite fees from the candidates

The candidates have to download the application form and send the filled in forms
with all necessary enclosures. Once we receive the physical form the same will be
scrutinized and if found eligible, a Registration No. will be allotted and
acknowledgement would be sent by e-mail.

Fees once paid would not be refunded under any circumstances.

The Hall Tickets would be sent three weeks before the commencement of the
examination.

The results of the written examination will be communicated to all the candidates and
also displayed on NPC web site.

10.0 ROLE OF NPC

The Central Boilers Board has retained the National Productivity Council (NPC) to
conduct the examination for Competent Persons and declare the results.

NPC will carry out the following activities: -

1.

Dr. Ambedkar Institute of Productivity (AIP), NPC, Chennai will receive and
process the applications from the candidates and register them as per the laid
down procedures.

2.

NPC will send all necessary instructions in respect of the Examination and
other details such as hall ticket, the venue of examination, timings, code of
conduct for the eligible candidates.
13

3.

NPC will administer the examination in four centres subject to the availability
of minimum number of candidates.

11.0 CONDITIONS AND INSTRUCTIONS TO THE CANDIDATES

1.

Candidates are advised to go through the prospectus before filling the

application form & all entries should be correctly filled.

2.

Attach proof of work experience certificate as per the eligibility criteria duly
certified by the competent authority.

3.

Attach an attested Photostat copy of Degree certificate as per the eligibility

criteria

4.

Level-II NDT Certificates from ISNT or any other professional body

recognized by ISNT in Non Destructive methods of testing in radiography and
ultrasonic testing certificate will be verified during viva voice.

5.

Affix three recent passport size photographs (one self attested in the
application form, one in the hall ticket and one in the Examination centre
check form).

6.

Enclose Demand Draft towards the fees in favour of National Productivity

Council, payable at Chennai.

7.

Candidates belonging to SC/ST category

will be required to submit the

attested copies of the necessary supporting documents as mentioned in the

prospectus and as per the formats applicable for Govt. of India. Other
formats issued in local languages will not be accepted.
8.

Candidates should have an E-mail ID (If you don't have an email account
please create one in free sites)

9.

Self addressed cover (24 cm x10cm) with duly affixed Indian postal stamp of
Rs.25/-.

10.

Candidates fulfilling the eligibility criteria need only to apply with necessary
enclosures.

11.

Filled-in application form with attested copies of enclosure along with requisite
fee should reach the following address on or before 21st August, 2015
Director & Head
Dr.Ambedkar Institute of productivity
14

National Productivity Council

6, Aavin Dairy Road, Industrial Estate North Phase,
Ambattur, Chennai 600 098
Tel. No. 044 26251808/26255216
Mobile:91- 9841401293
Fax No. 044 26254904
Email: rpmgchn.boiler@gmail.com
Website: www.npcindia.gov.in; www.aipnpc.in
Note: All correspondence related with Examination should be made to the
above address preferably on e-mail.

12.

The fees paid by a candidate who has been admitted to the Examination,
shall not be refunded or adjusted under any circumstances on the basis of
medical or any other ground.

13.

The candidates will have the responsibility to cross check the information on
allotted examination centres, issue of hall tickets and other instructions issued
from time to time, from the above mentioned website.

14.

Any candidate, who does not receive or loses the admission ticket, shall
report to the allotted examination centre with documentary evidence of having
registered for Examination. Information about allotted examination centres
may be seen at the web-site mentioned in the prospectus.

15.

(a) If a candidate on declaration of the results of Examination is not satisfied

with the marks given in any paper(s) and feels that there is possibility of either
omission in marking of any answer(s) or there is possibility of mistake in
totalling of the marks in any paper(s), the candidate may seek verification(retotalling) of all or any paper on his submitting an application accompanied by
a fee of Rs 400/- for each paper, to be paid by DD drawn in favour of
National Productivity Council payable at Chennai, within a weeks time
from the announcement of the result. NPC would check for re-totalling and
whether all the questions attempted by the candidates has been evaluated.

15

(b) The process of verification shall be completed with in a period of two

weeks from the date of receipt of the application by NPC.
(c) The marks obtained by a candidate in individual questions of paper(s) shall
not be supplied.
(d) Request for revaluation of Answer Books will not be entertained.
(e) Photocopies of evaluated Answer Books will not be made available to
candidates.

16.

Central Boilers Board Examination Standing Committee reserves the right to

change the examination dates / centres due to some unforeseen reasons and
reasons beyond its control.

17.

Applications received after the last date OR in any other format other than
the prescribed one OR incomplete will be summarily rejected. Delays in transit
and applications without relevant enclosures would be rejected without
assigning any reason.

18.

In all subsequent correspondence make sure that invariably you quote the
registration number, which you will receive in your acknowledgment by email.

19.

For any clarification. Contact us at rpmgchn.boiler@gmail.com

20.

For

Examination

updates

visit

website

:www.npcindia.gov.in

&

www.aipnpc.com

12.0 LIST OF ENCLOSURES TO BE ATTACHED WITH THE

APPLICATION
1

Proof for requisite educational qualification (Certificate should be attested by a

Gazetted Officer / Employer).

Proof for requisite experience in the prescribed format duly certified by the
employer.

DD in favour of National Productivity Council payable at Chennai.

Three recent passport size photographs (one self attested in the application
form, one in the hall ticket and one in the Examination centre check form).
16

5.

Proof of SC/ST certificates as per Govt. of India format in case of claiming fee
concession. Certificates issued in local languages will not be accepted.

6.

Duly filled Hall Ticket & centre check form along with photograph

7.

Proof of age.

8.

Self addressed cover (24 cm x10cm) with duly affixed Indian postal stamp of
Rs.25/-.

17

Annexure- I

13.0 SYLLABUS
Paper: 1 - Boiler Design Engineering
(Two hours, Open Book (IBR, 1950 & the Boilers Act, 1923), Descriptive Examination)
Water tube boilers: Classification of boilers- Natural circulation, Forced circulation,
Fluidized Bed Combustor Boiler (FBC), Circulating Fludized Bed Combustor Boiler
(CFBC), Waste heat boiler, Chemical recovery boilers, Cycles for Steam Power
Plants.
Once through boilers, Supercritical boiler and Ultra-supercritical boiler functions and
differences, advantages and disadvantages.
Solar Boilers, unfired boilers including thermic fluid boilers
Water circuit and steam circuit.
Fire tube boiler: Shell type boilers Horizontal and Vertical boiler, Various types of
furnaces, Furnace heat release rates for solid fuel and Oil fired Boilers, Methods of
various attachments in Shell and furnaces.
Boiler Design and Engineering :Design calculation methods factors to be
considered in designing a boiler, boiler layout, pressure part arrangement, pressure
and temperature drops across the boiler - temperature control methods, High
temperature properties (Hot yield, creep) of steel and design criteria for ascertaining
permissible stress and maximum temperature for use of each grade of steel - Design
calculation to ascertain maximum working pressure of parts, tubes exposed to hot
gases connecting pipes, headers, pipes and drums, ligament efficiency, method of
compensation for opening, method of attachment of tubes and branch pipes,
Longitudinal Stress, bending moment etc., weld coefficient.
Elements of feed water heaters Design and construction including tube expansion
methods.
Design & working pressure calculations for shell type boilers, ligament efficiency,
end plates / tube plates, tube design, furnace design, method of compensation for
openings, stay rods, gussets, stiffeners, pressure circle calculations etc.
Various boiler mountings and auxiliaries like fusible plugs, safety valves, safety valve
selection criteria and capacity calculation, electromatic safety valves, drum level
indicators, selection of feed water pumps etc.
Boiler components, piping, fitting, steam receivers, valves, steam traps, new
materials.
18

Criteria for adopting Pressure reducing and desuperheating stations (PRDS), Feed
water control system, Tees, elbows, bends and fittings.
Metal temperature calculations for various sections of boiler.

19

Paper 2 -Boiler Act and Indian Boiler Regulations and their compliance
(One Hour, Open Book (IBR 1950 & the Boilers Act, 1923), Multiple Choice
Questions (MCQ) type Examination
Boiler Act and Indian Boiler Regulations:
Salient Features of Boiler Act 1923 (as amended) and Indian Boiler Regulations,
1950 (as amended).
Materials
Materials used in boilers and their specification, methods of manufacture of
materials, Review of material certificate, material traceability, Positive material
identification, Acceptance of materials not fully identified, Tests done on plates /
pipes, tubes, forgings, castings and welding consumables.
Construction and workmanship
Cold and hot forming of plates, tubes and pipes heat treatment criteria after
forming.
Welding- Welding procedure, Welders / operator Qualification: Initial Qualification &
issue of certificate, Validity, Re-validation, age & experience for welders, Conditions
under which requalification test is required, Tests to be done on plate/Pipe & Tube
for Initial and Requalification Essential variables, Maintenance of records.
Welding processes : SMAW, GTAW, SAW, FCAW, GMAW, Combination welding,
Plasma, Flash butt welding, Induction Pressure welding, etc., welding consumables
and their classification, welding engineering (joint design, fit-up, weld & welding
symbols), reinforcement requirements, weld defects unique to each weld-fit-up
process and their acceptance norms, methods & norms for weld repairs.
Welding Consumables - initial/periodic check tests as per IBR
Preheating, Post heating and Post weld heat treatment: Criteria for application of
PWHT for Shells, Drums, Headers, piping, Tubular products, method of loading,
calibration of furnaces and measuring instruments, soaking temperature / time, Rate
of heating / cooling.
Non-destructive Testing: Mandatory NDT requirements for various welds on tubes,
pipes, headers and drums.
Mechanical testing of production test coupon.

20

Tensile Test: Tensile test, basic principle, types of tensile tests, significance of allweld and transverse tensile tests, specimen extraction procedure, preparation &
dimensional details of all-weld and transverse tensile specimens, testing procedure,
calculation procedure for YS, UTS, % E, %RA, interpretation of test results as per
IBR code.
Bend Test: Root bend, face bend, side bend tests, significance & application of each
test, preparation & dimensional requirements of specimens, criteria for selection of
mandrel diameter, angle of bend, Bend test procedure for plates, tubes & pipes,
interpretation of test results as per code.
Impact test: Basic principle of impact test, types of impact test, location, preparation
& dimensional requirements of specimens, selection of test temperature as per
regulation, testing procedure, interpretation of test results as per regulations.
Macro examination: Specimen preparation procedure, macroscopic examination
procedure, observable defects, interpretation as per regulation.
Micro Examination: Specimen preparation procedure, microscopic examination
procedure, selection of magnification range, observable defects, interpretation as per
regulation.
Procedure for open inspection of water tubes and Fire tubes boilers.
Hydraulic test:
Hydraulic test of boilers & various components like Drums, Headers, piping, tubular
products at works.
Hydraulic test of boilers at site after erection and for renewal of certificate for use of
boiler.
Venting, Test pressure, Number of calibrated gauges, Holding time, method of
Inspection, Makers stamp as stipulated in regulation.
Inspection & Certification:
Stages of Inspection during manufacture of Boiler/Boiler Components, different
forms and their applicability.
Fees for approval of drawings/design, inspection during manufacture, erection,
registration.
Calculation of heating surface area of boilers and its components
Exemptions as per Act

21

Paper 3 - Boiler Act, Regulation, Materials, erection, commissioning,

operation and maintenance
(Three hours, No-Book, Descriptive Examination)

Boiler Act and Compliance

Boiler Act and its provisions, Definition of terms like Accident, boiler, Pipelines,
Manufacturer, Owner, Inspecting Authority, Competent Person, etc., Procedure for
certification, registration and renewal of boiler, Role and responsibilities of competent
person, Inspector, Chief Inspector, Inspecting Authority, Competent Authority.
Materials
Classification of materials, Classification of steels, boiler materials, basic metallurgy,
weldability of materials, plates , pipes, tubes, casting and forgings of boiler quality
and welding electrodes, process of steel manufacturing, chemical composition,
mechanical properties, tolerances, knowledge on equivalent international materials
used in boiler manufacture ,well known steel /forge/foundry/ pipe / tube maker etc
requirements, procedures, inspection and testing to be done in the absence of well
known recognitions, new materials.
Construction and workmanship
Welding- Welding procedure, Welders Qualification, Initial Qualification & renewal for
welders, Conditions under which requalification test is required, tests to be done on
plate/Pipe & Tube for Initial and requalification, Essential variables.
Welding processes : SMAW, GTAW, SAW, FCAW, GMAW, Combination welding,
Plasma, Flash butt welding, Induction Pressure welding, etc., welding consumables
and their classification, welding engineering (joint design, fit-up, weld & welding
symbols), reinforcement requirements, weld defects unique to each weld-fit-up
process and their acceptance norms, methods & norms for weld repairs.
Welding Consumables - initial/periodic check tests on consumables as per IBR.
Preheating, Post heating and Post weld heat treatment, Criteria for application of
PWHT for Shells, Drums, Headers, piping, Tubular products, method of loading,
calibration of furnaces and measuring instruments, soaking temperature / time, Rate
of heating / cooling .
Different process adopted in welding of tubes, pipes, Shells, Visual Inspection of
welds, reinforcement requirements, acceptance norms for weld defects, norms &
method for weld repairs.
22

Non-destructive Testing: Mandatory NDT requirements for various welds on tubes,

pipes, headers and drums, Qualification of NDE personnel.
PT- Liquid Penetrant Testing
Principles of liquid penetrant process, Lighting for liquid penetrant testing Materials
for liquid penetrant testing, Testing of materials, Interpretation/Evaluation, Factor
affecting
indications,
Indications
from
discontinuities,
Procedures,
Codes/Standards/Specifications. Non relevant indications.
MT- Magnetic Particle Testing
Characteristics of magnetic fields and equipments, Technique/Calibrations, Selecting
the proper method of magnetization, Magnetic particle test indications and
interpretations, Procedures, Codes/Standards/Specifications. Non relevant
indications.
RT-Radiographic Testing
Principles Radiographic imaging, Sources for radiation, Techniques / Calibration,
Imaging considerations, Image Quality Indicator (IQI), Density of material, Viewing
of radiographs, Judging radiographic quality, Interpretation and Evaluation:
Radiographic appearance of discontinuities, Non-relevant indications, Film artifacts,
Film
identification
and
correlation
of
the
weld,
Procedures,
Codes/Standards/Specifications.
UT-Ultrasonic Testing
Principles, Equipment/Materials, Pulse/echo instrumentation, Calibration blocks,
Techniques/Calibrations, Use of all types of probes, Calibration(electronic and
functional), Interpretation and Evaluations: Evaluation of base metal, product forms,
Evaluation of weldments, Variables affecting test results, Procedures,
Codes/Standards/Specifications.
Radioscopy Test (Fluoroscopy).
Field installation and registration
Review of document of boiler parts as received and correlation to the corresponding
part - Verifying the qualification of welders, NDE personnel etc, review and remedial
action, Inspection during field installation w.r.t parts identification, Weld setups,
Welding and non destructive examination. Evaluation of field welds by RT, UT, HT or
PT or by combination.
Heat Treatment where applicable method for local HT and controls - Witnessing final
Hydraulic test before thermal insulation, water quality and temperature, Safety Valve
set / reset pressure, discharge capacity, Safety valve set pressure and discharge
23

capacity for waste Heat Boiler with auxiliary firing, Water level indicator and use of
remote Water level indicator, Steam pipe lines cold / hot condition flexibility and
hanger settings, Verification of instruments to measure metal temperature, Steam
temperature and pressure, Protection of boilers through burner management system
(Fuel cut off systems, flame scanner and trips , interlocks etc.).

Documentation for registration of boilers.

Inspection & Certification:
Stages of Inspection during manufacture of Boiler/Boiler Components, erection and
use of different IBR forms and their applicability, Memorandum of Inspection or
registration Book (Form I) and its salient features.
Requirements for Registration of boilers.
Repair and Renewal of Certificate for use of Boilers:
Procedure for Inspection and repair of Installed Boilers & Steam pipes.
Boiler Operation and Maintenance
Chemical requirements of feed water, Boiler water, steam quality for low, medium
pressure, high and super-critical Boilers, sampling methods, test method, Carryover,
scale and sludge, scaling of fireside of heating surfaces, steam contamination and its
control, prevention of deposit formation in boiler units, corrosion of heating surfaces,
Start & stop sequence, operation procedure, critical boiler parameters, alarms and
annunciations, contingency action plan, safety precautions.
Boiler emergencies How to handle
Boiler explosions Reasons and Preventions
Boiler repairs Methods and procedure, Failure analysis
Thick walled component repair at site Precautions and limitations, Preheating and
post heating, Post Weld Heat Treatment
Maintenance schedule shutdown maintenance, procedure, safety precautions,
work permit system, restarting procedure , acid cleaning, hydraulic test, light up of
boiler, commissioning
Data acquisition and analysis Broad idea, importance
Boiler inspection periodicity, methods, procedure

24

In service periodic inspection

Review mandatory requirements of operating boilers, Procedures for conducting
periodic hydraulic test of operating boilers, Elements of mode of failures of metals,
Assessment of condition of boilers: - Review past record of boilers w.r.t. failures,
outages, repairs / replacements of pressure parts, Visual inspection of external &
internal surfaces for visible damages, loss of metal by erosion/corrosion, condition of
tube supports, spacers etc., fire side scaling, ash/slag fouling, Boilers with record of
frequent failures may require detailed investigation by conducting NDE using Dye
penetrant / magnetic particle test for detecting cracks or UT to determine thickness
of tubes or cracks in dissimilar welds / fillet / butt weld cracking or RT insitu
metallurgical examination, Conducting laboratory examination on tube samples for
erosion / corrosion, creep damage, hydrogen embrittlement, Stress Corrosion
Cracking, Oxygen pitting, Oxidation, fire side fouling, water side deposits and need
for chemical cleaning etc., Authorization for repairs & replacement, Verifying the
condition of safety valves, water level gauges and other mounting, instruments for
measuring temperature and pressure and fire protection systems and interlocks,
Isolation of steam and water circuits in battery of boilers and other safety measures.
Remnant Life Assessment (RLA) of boilers
Criteria for R L A Tests required for various boiler components,
methods for remaining life.

Evaluation

Fuel Air Gas system

Basics knowledge in the areas like Primary fuels, principles of combustion,
chemistry of combustion, pulverized coal fired furnaces, fuel oil and gas fired
furnaces, controls and instrumentation and their effect on boiler functioning.
Isolation of Fuel/Flue Gas during inspection.
Layout and Sketches
Layout and Sketches of boilers & boiler components, steam & feed water circuits and
their parameters.

25

ABOUT NATIONAL PRODUCTIVITY COUNCIL

NPC is a national level organization to promote productivity culture in India. Established as
a registered society by the Government of India, it is an autonomous tripartite, non-profit
organization with equal representation from the government, employers and workers
organizations apart from the technical and professional institutions on its governing council.
NPC provides consultancy, training and undertakes research in the area of productivity,
besides implementing the productivity promotion of the Tokyo based Asian Productivity
Organization, an inter-governmental body of which the Government of India is a founder
member.
SPECTRUM OF SERVICES
NPC has more than five decades of experience deploying the best practices, preferred
methods & standards and advanced productivity software across a spectrum of industries
and services. The organization specializes in a wide range of services to promote
productivity, competitiveness and cost effectiveness through.
Awareness Generation : Propagating productivity quality and competitiveneness through
seminars, workshops, publications and other suitable methods.
Consultancy : Improving productivity for competitiveness through consultancy work of the
private and public corporate sectors. SMEs, Governments and other client groups.
Training : Training of executive managers, workers, supervisors and others
Research : Conducting research studies and surveys on productivity and related matters.
ENTERPRISE LEVEL:
Process Management : Total Quality management, ISO 9000 certification, Business Process
Re-engineering, KAIZEN, Benchmarking, Customer Relations Management (CRM).
Information Technology : Management Information System, E-governance, IT Infrastructure
Planning.
Energy Management : Energy Audits, Co-operation, Demand side Management, Renewable
and Green Energy Sources, Process Optimization and Energy Conservation.
Environment Management : Integrated Environment Planning, Environment Audit, Cleaner
Production Techniques, Hazardous Waste Management, Waste Minimization and
Utilization, Green Productivity, ISO 14000 & OSHAS 18000.
Economic Services : Policy Research and Consultancy, Productivity Audit.
26

Human Resources Development : Work Culture, Participative Group Activities, Work Load
Assessment, Organization Redesign, Productivity Linked Reward/Wages Scheme, Training
needs Assessment.
Technology Management : Condition Monitoring, Safety Audit, Assessment, Total
Productivity Maintenance.
World Class Manufacturing : Flexible/Cellular Manufacturing, Time Reduction, Six Sigma.
Agribusiness : Food Processing, Soil and Water Conservation.

27

What we know is only a handful

What we dont know is an ocean
- Avvaiyar, Tamil poet, 2 AD.

For any further details, please contact

Director & Head

Dr.Ambedkar Institute of Productivity
National Productivity Council
6, Aavin Dairy Road,
Industrial Estate North Phase, Ambattur,
Chennai 600 098
Tel. No. 044 26251808
Mobile:91- 9841401293
Fax No. 044 26254904
Email: rpmgchn.boiler@gmail.com
Website: aipnpc.in;www.npcindia.gov.in

28